Allen-Bradley 1395 Troubleshooting Manual

Type
Troubleshooting Manual
Troubleshooting Guide
1395 Digital DC
Drive
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Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. “Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls” (Publication SGI-1.1
available from your local Rockwell Automation Sales Office or online at
http://www.ab.com/manuals/gi) describes some important differences
between solid state equipment and hard-wired electromechanical devices.
Because of this difference, and also because of the wide variety of uses for
solid state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is
acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for
indirect or consequential damages resulting from the use or application of
this equipment.
The examples and diagrams in this manual are included solely for
illustrative purposes. Because of the many variables and requirements
associated with any particular installation, Rockwell Automation, Inc.
cannot assume responsibility or liability for actual use based on the
examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to
use of information, circuits, equipment, or software described in this
manual.
Reproduction of the contents of this manual, in whole or in part, without
written permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual we use notes to make you aware of safety
considerations.
Attentions help you:
identify a hazard
avoid the hazard
recognize the consequences
Important: Identifies information that is especially important for successful
application and understanding of the product.
!
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
damage, or economic loss.
Shock Hazard labels may be located on or inside the drive to
alert people that dangerous voltage may be present.
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Table of Contents
Chapter 1 Understanding the Basic Principles
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ESD Sensitivity Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Facts to Read Before Proceeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Chapter 2 Malfunctions with Indications
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Hard Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Soft Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Warning Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Fault Response Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Fault Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Fault Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Bulletin 1300 Programming Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Fault Descriptions and Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Fault Display on HHT or DHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
System Processor Faults (SP–XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Velocity Processor (VP–XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Current Processor Faults (CP–XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Final Fault Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Chapter 3 Malfunctions Not Indicated by a Fault
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Logic Control Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Link/Configuration Parameter Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Velocity Control Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Velocity Feedback Device Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Encoder Device Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Analog Tachometer Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Armature Current Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Main Control Board Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Field Current Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Magnetics/Power Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Series A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Series B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Auto Tuning Malfunctions (Series A & B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Chapter 4 Using Trending to Aid Troubleshooting
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Trend Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Examining Trend Data With a Program Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Examining Trend Data with the Node Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Examining Trend Data with the Discrete Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Examples of Trends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
System Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Ground Network Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Electrical Noise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
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2 Table of Contents
Chapter 5 Manually Tuning the 1395 Drive
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Tools & Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Current Loop Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Velocity Loop Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Field Flux Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Chapter 6 Test Points
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Power Stage Interface/Switcher Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Power Stage Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Appendix A Parameter List/Record
General Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Drive Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Wiring and Control Board Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Measurement Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Parameter Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Index
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Chapter 1
Understanding the Basic Principles
General
This guide is intended to help you define troubleshooting techniques and
procedures and help simplify servicing of the Bulletin 1395 DC Drive by
identifying likely causes for malfunction. The 1395 employs extensive
diagnostics to aid in correcting many malfunctions that may occur in the
system. This guide is designed to help interpret the diagnostic response of
the Drive when a malfunction occurs. It will also aid in diagnosing
malfunctions that do not solicit a fault response from the Drive. Possible
corrective measures will be explained to help get the Drive repaired or
functional as quickly as possible for all types of malfunctions.
Required Equipment
In addition to a Bulletin 1300 Programming Terminal the following should
be available before initiating any troubleshooting procedures:
Digital Multimeter (DMM) capable of 1000VDC/750VAC, with a one
megohm minimum input impedance.
Assorted screwdrivers (Phillips and Straight).
Clamp on Ammeter (AC/DC) with current ratings to 3X rated armature
current output of 1395.
Dual trace oscilloscope with differential capability, digital storage, with
two X10 and one X100 calibrated probes. (Optional but recommended.)
Hand Tachometer used to monitor motor velocities.
Bulletin 1395 Installation Manuals for:
Programming Terminal (Bulletin 1300)
Adapter Boards
!
ATTENTION: Only personnel familiar with the 1395 Drive
System and the associated machinery should perform
troubleshooting or maintenance functions on the Drive. Failure
to comply may result in personal injury and/or equipment
damage.
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1-2 Understanding the Basic Principles
ESD Sensitivity Precaution
During Start-up the following information should have been recorded for
reference during troubleshooting. If it was not, record the following at this
time:
An accurate list of Drive Setup and Configuration parameters, in case the
EEPROM is corrupted. Tables are supplied in Chapter 6 for this purpose.
Software Version numbers should be recorded for each board. These are
necessary to provide to on-site personnel or when calling for assistance.
Drive and motor nameplate data should have been recorded at start-up
and maintained for ready reference during troubleshooting. Many
systems do not allow for easy access to the motor after startup. If the
motor nameplate data was not recorded previously, attempt to do so at
this time.
!
ATTENTION: This Drive may contain ESD (Electrostatic
Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with
static control procedures, reference U.S. Department of Defense,
DOD-HDBK-263, Electrostatic Discharge Control Handbook for
protection of Electronic Parts, Assemblies and Equipment or any
other applicable ESD Protection Handbook.
!
ATTENTION: When replacing boards containing firmware
EPROM modules, Do Not transfer EPROMs from the damaged
board to the replacement board. Electrostatic Discharge (ESD),
Electromagnetic Interference (EMI), excessive heat,
contamination of printed circuit boards (PCB), and connections
that are damaged or improperly seated, etc., can cause serious
malfunctions to occur in the 1395 drive. An attempt should be
made to correct any of these environmental conditions prior to
installing new components.
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Understanding the Basic Principles 1-3
Safety Facts to Read Before
Proceeding
!
ATTENTION: Severe injury or death can result from electrical
shock, burn, or unintended actuation of controlled equipment.
Hazardous voltages may exist in the cabinet even with the circuit
breaker in the off position. Recommended practice is to
disconnect and lock out control equipment from power sources,
and discharge stored energy in capacitors, if present. If it is
necessary to work in the vicinity of energized equipment, the
safety related work practices of NFPA 70E, Electrical Safety
Requirements for Employee Workplaces, must be followed. DO
NOT work alone on energized equipment.
!
ATTENTION: Potentially fatal voltages may result from
improper usage of oscilloscope and other test equipment. The
oscilloscope chassis may be at a potentially fatal voltage if not
properly grounded. If an oscilloscope is used to measure high
voltage waveforms, use only a dual channel oscilloscope in the
differential mode with X 100 probes. It is recommended that the
oscilloscope be used in the A minus B Quasi-differential mode
with the oscilloscope chassis correctly grounded to an earth
ground. Refer to equipment safety instructions for all test
equipment before using with the 1395.
!
ATTENTION: The CMOS devices used on the control circuit
boards can be destroyed or damaged by static charges. If
personnel will be working near static sensitive devices, they must
be appropriately grounded. If you are not familiar with static
control procedures, reference A-B publication 8000-4.5.2
Guarding Against Electrostatic Damage or any other applicable
ESD Protection Handbook.
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1-4 Understanding the Basic Principles
Notes:
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Chapter 2
Malfunctions with Indications
General
Most malfunctions that occur induce a fault response from the 1395 drive.
This aids greatly in determining what malfunction has occurred. By
recording all of the faults indicated by the 1395 and using the
accompanying information, most problems can be corrected. The 1395
employs extensive diagnostics which monitor both internal and external
operating conditions and responds to incorrect conditions as programmed
by the user.
Hard Faults
A Hard Fault is the highest priority fault which indicates a condition in
which the 1395 has detected an internal malfunction and has determined
that operation can no longer continue. This type of fault indicates that a
major internal component or system has malfunctioned and that control of
the drive functions may be lost. The response of the drive to a Hard Fault is
a coast stop or whenever possible, a controlled motor stop.
A rotating motor will stop according to the Torque Mode commanded. The
following is an example of the action that will occur based on the value of
Parameter 625 “Torque Mode”
1. If Parameter 625 = 0 (Zero Torque) the drive will immediately phase
back the armature bridge and open the DC contactor.
2. If Parameter 625 = 1 (Velocity Regulate) the Drive will ramp the motor
velocity to zero and then open the contactor.
3. If Parameter 625 = 2 (External Torque Regulate) the Drive will
immediately phase back the armature bridge and open the DC contactor.
4. If Parameter 625 = 3 (Min Select) the Drive will immediately phase back
the armature bridge and open the DC contactor.
5. If Parameter 625 = 4 (Max Select) the Drive will immediately phase
back the armature bridge and open the DC contactor.
6. If Parameter 625 = 5 (Load Response) the Drive will immediately phase
back the armature bridge and open the DC contactor.
When a Hard Fault has occurred, fault recovery can only be accomplished
by initiating a system RESET or cycling AC line power. Examples of Hard
Faults include:
Handshake Fault - A fault between processors that indicate communication
or functionality was lost by one, or both processors.
Internal Memory Fault - A fault detected by a processor that indicates a
component malfunction.
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2-2 Malfunctions with Indications
Soft Faults
A Soft Fault indicates a condition in which the 1395 has detected a
malfunction that could cause damage to the drive control, power
components, or the motor. It may also indicate that undesirable operating
conditions exist external to the drive. This type of fault is used to protect the
drive system components from damage due to both internal and external
malfunctions. It differs from the Hard Fault in that the 1395 can, in most
cases, maintain proper control during the fault.
A Soft Fault is a second priority fault. When it occurs the response of the
drive is to initiate a coast stop or controlled motor stop. Fault recovery is
accomplished by a Clear Fault command, a system RESET command, or by
cycling AC line power.
Examples of Soft Faults are:
Velocity Feedback Loss - Fault detected when the selected feedback device
malfunctions. The drive will respond with a coast stop.
SCR Overtemperature Trip - detected when the thermal switch opens on the
power structure heat sink. The drive will respond by initiating a controlled
motor stop.
Warning Faults
A Warning Fault is the lowest priority fault which indicates a condition that
if left uncorrected, could result in a Soft Fault. This type of fault is designed
to annunciate a condition present in the system. When a Warning Fault
occurs, the appropriate Fault Code is entered into the Fault Queue and the
Fault Status parameters reflect the condition present. The drive will not
command a stop, and operation will continue unaffected. Fault Recovery is
accomplished by initiating a Clear Fault command, but is not necessary for
continued operation. Examples of Warning Faults are:
Motor Overload Pending - Detected when the armature current exceeds
115% (default value of parameter 720) of the motor armature current rating.
The drive will respond by indicating a Warning Fault and entering a
message into the Fault Queue, if parameter 632, bit 0 is set to zero.
Bridge Overload Pending - Detected when the armature current exceeds
105% of the bridge rating. The drive will respond by indicating a Warning
Fault, and entering a message into the Fault Queue, if parameter 632, bit 2 is
set to zero.
Fault Response Selection
A number of fault conditions in the 1395 may be configured to respond as
either Soft or Warning type faults. This allows the user to control the
response of the drive to some fault conditions based on his unique
application requirements. Parameter 623 “Fault Select” is a bit coded word
which controls whether eight predetermined faults will cause a Soft or
Warning type response. Bit definitions for parameter 623, corresponding to
the eight faults, are given in
Table 2.A. A fault condition will cause a Soft
Fault at this time.
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Malfunctions with Indications 2-3
A Soft Fault response will occur if the corresponding bit is set to 1. A
Warning response will occur if the corresponding bit is set to 0.
The default for all bits of parameter 623, when the parameter table is
initialized, is 1. This causes all of the faults listed in
Table 2.A to respond as
a Soft Fault type. For a fault to respond as a Warning Fault, the
corresponding bit must be set to 0 by the user. If the faults above are
configured as Warning Faults, then a provision should be made to report
these warnings through the PLC or other external device.
Configuring “Waiting Safe Arm Volts” (bit 5=0) and “Waiting Zero Arm
Current” (bit 6=0) as Warning faults is recommended. This allows the
current loop to attempt to correct the condition without causing nuisance
trips. Drive operation is continued even when these faults are configured as
Warning Faults. ALL other bits should be set to 1 in most applications.
Three warning faults can be disabled by bit manipulation of parameter 632:
If a bit is set to 1, that particular fault will not be reported in the fault
word (parameter 100).
Table 2.A Fault Select Parameter 623
Parameter 632 Associated Fault
Bit 0 = Motor Overload Pending VP-16, (reference parameter 720)
Bit 1 = Excessive armature volts demand VP-36
Bit 2 = Bridge Overload Pending VP-39 (reference parameter 615)
Bit
Fault
Number Fault Definition Fault Description
0 VP-14 SCR Overtemp Occurs when the SCR heat sink (HST) thermo switch reaches 85 degrees C (185
degrees F) for 1 second. If bit 0 = 1, then a fault occurrence will cause a controlled
motor stop.
1 VP-15 Motor Overtemp Occurs when the external overtemp discrete input is low for specified delay of
Param 725. If bit 1 = 1, then a fault occurrence will cause a controlled motor stop.
2 VP-17 Overload Tripped Occurs when the armature current output has exceeded the selected motor
overload coefficients. These coefficients are selected in parameter 629 “Mtr
Overload Sel”. If bit 2 = 1, then a fault occurrence will cause a controlled motor stop.
3 VP-18 Stall Occurs when the armature current output is at current limit and velocity is within the
zero speed tolerance (parameter 710) for the time specified in parameter 727 “Stall
Delay”. If Bit 3 = 1, then a fault occurrence will cause a Coast Stop.
4 VP-20 AC Voltage Occurs when the incoming AC line voltage exceeds +15% or–20% of voltage
specified in parameter 617 “Rated AC Line” for 1 second. If Bit 4 = 1 then a fault
occurrence will cause a controlled motor stop.
5 VP-34 Waiting Safe
Arm Voltage
Occurs when armature CEMF is too high to allow successful commutation during a
forward to reverse bridge change. If bit 5 =1, then a fault occurrence will cause a
Coast Stop. If bit 5 = 0, then an occurrence will cause the motoring bridge to be
held off, allowing the motor to coast to a lower CEMF. When an acceptable level is
reached the drive will allow a bridge change and operation will continue.
6 VP-35 Waiting Zero
Arm Current
Occurs when the armature current does not go to zero when a bridge change is
commanded. If bit 6 = 1, then a fault occurrence will cause a Coast Stop. If bit 6 = 0,
then an occurrence will cause the drive to attempt to force the current to zero.
7 VP-31 Arm Bridge
Overload Trip
Occurs when armature current output exceeds the predetermined armature bridge
overload coefficients which are based on 150% for 60 seconds, 200% for 10
seconds, 260% for 5 seconds. If bit 7 = 1, then a fault occurrence will cause a Coast
Stop.
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2-4 Malfunctions with Indications
Fault Setup Parameters
Certain Faults have setup parameters associated with them. They allow the
user to set thresholds and time delays according to the particular
application. A description of faults with setup parameters follows:
No. Name Description Associated Parameter(s)
VP-10 Feedback
Loss
This Soft fault occurs when the
measured velocity feedback from
the selected feedback device is less
than parameter 732 “Tach Loss Vel”
and the CEMF of the motor is
greater than parameter 731 “Tach
Loss CEMF”.
Velocity Fdbk (106) < Tach Loss Vel
(732), AND calculated CEMF from
Arm Voltage Fdbk (105) > Tach Loss
CEMF (731), THEN Fault on
Feedback Loss.
Parameter 731 “Tach Loss CEMF”. This
parameter indicates the lower limit of CEMF of
the motor voltage allowed for determination of
feedback loss. Programmable range is 0-33%.
Parameter 732 “Tach Loss VEL” This parameter
indicates the upper limit of velocity feedback
measured by the selected feedback device
allowed for determination of feedback loss.
Programmable range is 0.244, ±10%.
Parameter 731 “Tach Loss CEMF” must always
be programmed to a value greater than
parameter 732 “Tach Loss VEL or nuisance trips
will occur.
VP-12 Absolute
Overspeed
This Soft fault occurs when motor
velocity exceeds the maximum
forward/reverse speed limits by the
absolute overspeed level.
Parameter 724 “ABS Overspeed” This
parameter indicates the incremental motor
velocity (RPM) above parameter 607 “Rev
Speed Limit” or parameter 608 “Fwd Speed
Limit” that must be detected in parameter 106
“Velocity Fdbk” to cause the above fault.
Programmable range is zero to Base Speed.
See also parameters 607 “Rev Speed Limit” and
608” Fwd Speed Limit”.
VP-13 Motor Field
Loss
This Soft fault occurs when the field
current feedback is less than 50% of
field current reference for the time
delay specified.
Parameter 730 “Fld Failure Dly” This parameter
indicates the time the field current feedback
must remain less than 50% of the field current
reference before the above fault is indicated.
Programmable range is 0-5 seconds.
Parameter 627 “Flux Mode Select”. Bit 6 can be
used to disable field loss detection. For normal
operation, set it to 0 to detect field loss
conditions.
VP-14 SCR
Overtemp
This fault occurs when the SCR heat
sink (HST) thermoswitch and/or
vane switch (MKVA) opens after the
specified time delay.
Parameter 726 “SCR Overtemp Dly”. This
parameter indicates the time the thermoswitch
must remain open before the above fault is
indicated. Programmable range: 0-3276.7 secs.
VP-15 External
Overtemp
This selectable fault occurs when
the external overtemp discrete input
(TB3-1& 2) is low for the time delay
specified.
Parameter 725 “Motor Ovtemp Dly”. This
parameter indicates the time the discrete input
must remain low before the above fault is
indicated. Programmable range: 0-3276.7 secs.
Verify that the motor thermostat is properly
wired. If the motor is not equipped with a
thermostat, 115 VAC or 24V DC must still be
applied to TB3 terminal 2. See 1395 Installation
Manual (publication 1395-5.40).
!
ATTENTION: Uncontrolled motor rotation can cause injury or equipment damage i
f
field loss detection is disabled. Field loss protection can only be disabled if using a
n
external field supply. Set bit 6 to disable field loss detection.
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Malfunctions with Indications 2-5
Fault Status Indicators
The Bulletin 1395 contains various Fault Status Indicators which can be
used to monitor the faults that occur in the drive. These are available for use
with the Bulletin 1300 Programming Terminal (DHT/DMT), the PLC/Node
adapter, the PLC/Data Highway +, the Multi Communication Adapter and
through the use of discrete I/O devices.
VP-16 Thermal
Overload
Pending
This Warning fault occurs when the
armature current exceeds the Motor
Overload Pending Level.
Parameter 720 “Ovrld Pend Level”. It is used to
indicate that the present armature current output
exceeds a predetermined level and continued
operation at this level may cause damage to the
motor and/or process. This warning fault can be
disabled. Refer to Parameter 632.
VP-17 Thermal
Overload
Tripped
This selectable fault occurs when
armature current output over time
has exceeded the selected motor
overload coefficients.
Parameter 629 “Mtr Overload Sel”. This
parameter is used to select the coefficients for
the motor thermal overload function.
0. Overload function disabled
1. 60 seconds to trip at 150% armature current
for externally cooled motors.
2. 60 seconds to trip at 200% armature current
for externally cooled motors.
3. 60 seconds to trip at 150% armature current
for self cooled motors.
4. 60 seconds to trip at 200% armature current
for self cooled motors.
VP-18 Motor
Stalled
This selectable fault occurs when
the armature output is at current
limit and velocity is within the zero
speed tolerance for the time delay
specified.
Parameter 727 “Stall Delay”. This parameter
indicates the time that the armature current must
remain at current limit with the motor velocity
within the zero speed tolerance before the above
fault is indicated. Programmable range: 0-100
seconds.
See also parameters 663 “Fwd Brdg Cur Lim”,
664 “Rev Brdg Cur Lim”, and 710 “Zero Speed
Tol”.
VP-20 AC Voltage This selectable fault occurs when
the incoming AC line voltage
exceeds +15% or –20% of rated AC
line voltage for the time delay
specified.
Parameter 617 “Rated AC Line”. This parameter
indicates the incoming AC line voltage and is
used as a basis for the above comparison and
resulting fault. Programmable range: 150-460V.
Parameter 728 “AC Line Tol Dly”. This parameter
indicates the time the AC Line must remain out
of tolerance before the above fault is indicated.
Programmable range: 0-1.0 secs.
No. Name Description Associated Parameter(s)
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2-6 Malfunctions with Indications
Fault Status Indicators
Parameter Name Description
100 Logic
Status
Parameter 100 uses bits 0 and 1 to indicate the highest priority fault level
present in the drive. The two bits are binary coded to allow for four
different indications. This source configuration parameter can be linked to
various adapters depending on the application. It can also be monitored
by the Programming Terminal.
101 Drive
Fault
Parameter 101 is a bit coded source configuration parameter that can
report the status of Soft and Warning Faults that exist in either the Current
Processor or Velocity Processor. The selection between Current
Processor or Velocity Processor faults is made in the setup parameter 630
“Fault Report”.
630 Fault
Report
Parameter 630 is a setup parameter which determines whether the
Current or Velocity Processor faults will be reported. If parameter 630 = 0,
then Current Processor faults will be reported in parameter 101. If
parameter 630 = 1, then Velocity Processor faults will be reported in
parameter 101. The corresponding bit definitions can be found below.
Bit 1 Bit 0 Definition
0 0 No Fault
0 1 Warning Fault
1 0 Soft Fault
1 1 Hard Fault
Bit Fault Definition(630=0) Fault Definition(630=1)
0 CP-06 Phase Loss VP-10 Feedback Loss
1 CP-05 Logic Power Supply ECOAST Status (0=Closed,
1=Open)
(1)
(1)
Bit 1 ECOAST Status is not a fault indicator but does allow the operator to
monitor, through a source configuration parameter, whether the ECOAST circuit
is closed. The ECOAST string allows the drive to close the DC contactor. If the
string is closed bit 1 will be set to 0 and the DC contactor will be allowed to close
if commanded. If the circuit is open then bit 1 will be set to 1 and the DC
contactor will be held open.
2 CP-08 AC Overcurrent Trip VP-12 Absolute Overspeed
3 CP-09 DC Fault (Overcurrent) VP-13 Motor Field Tolerance
4 CP-07 Overcurrent Trip (AC/DC) VP-14 SCR Overtemp
5 VP-31 Arm Bridge Overload Trip VP-15 External Overtemp
6 VP-32 Motor Field Loss VP-16 Thermal Overload Pending
7 Defined for internal use only VP-17 Thermal Overload Tripped
8 VP-34 Waiting Safe Arm Voltage VP-18 Motor Stalled
9 VP-35 Waiting Zero Arm Current VP-19 Contactor Failure
10 Excessive Arm Voltage Demand VP-20 AC Voltage
11 Defined for internal use only VP-21 VP Handshake with SP
12 Defined for internal use only VP-22 VP Handshake with CP
13 VP-39 Arm Bridge Overload Pend VP-23 SP Mode Request Not
Honored
14 Not Used VP-24 CP Not in VP Requested Mode
15
(2)
Status of Param 630 “Fault Report” Status of Parameter 630 “Fault
Report”
(2)
Bit 15 in either selection reflects the present status of parameter 630
“FaultReport”. If bit 15 is 0 then the Current Processor Fault status is being
reflected in parameter 101. If bit 15 is 1 then the Velocity Processor Fault Status
is bein
g
reflected.
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Malfunctions with Indications 2-7
Bulletin 1300 Programming
Terminal
You can also use the Bulletin 1300 Programming Terminals to monitor the
terminal fault status of the 1395 drive. Any of the fault status parameters
(100, 101, 630) can be monitored through the Programming Terminal. Use
Main Menu item 3 “Parameter”.
In addition, when a Hard or Soft Fault occurs, the fault message will appear
immediately on the screen of the programming terminal. To view all of the
faults in the Fault Queue, select Main Menu item 7 “Faults”. Then select
Fault Menu Item 1 “View Faults” to view the last 16 faults that occurred.
Use the INC/DEC keys to move through the Fault Queue for that processor.
Use the ENTER key to view other processor’s fault queues if they exist. All
types of detectable faults that have occurred will be present in the Fault
Queue.
Any problems with the Programming Terminal itself will be evidenced by a
missing or non-active Pendulum on the initial display. If programming
terminal problems are suspected, refer to the terminal instruction manual.
Fault Descriptions and
Recovery
Each processor in the 1395 drive has unique fault detection and message
capabilities which it can generate. These fault diagnostics can consist of
Hard, Soft, or Warning type faults and can cause the drive to respond in
various ways. The faults detected by each processor are listed, along with a
complete description, possible causes and possible fault recovery
procedures that will allow the malfunction to be corrected.
A recurring fault, as referenced below in the Recovery procedure, refers to a
fault that repeats as soon as normal operation is attempted. Faults that
reoccur at random intervals may be due to a transient condition and not
necessarily a board or component malfunction.
Fault Display on HHT or DHT
System Processor Faults
(SP–XX)
In general most System Processor faults indicate that an internal processor
error somewhere in the 1395 system has occurred. These faults can be
induced by Electrostatic Discharge (ESD), Electro Magnetic Interference
(EMI), excessive heat, contamination of printed circuit boards (PCB),
connections that are damaged or do not seat properly, etc. An attempt
should be made to correct any of these environmental conditions prior to
replacing components in the drive. This should reduce the possibility of
reoccurrence. If board replacement is necessary, replace the complete
board, DO NOT reuse EPROM chips.
No. Name Description Recovery
10 Comm Fault Attempting to
re-establish
communication.
1. Drive may be held in a continual reset. If
Reset/Stop input TB3-3, is held high (24 or
115 volts applied). and parameter 620 = 0
(Default setting), Drive will be in a continual
reset. Set parameter 620 to a non zero value.
2. Check integrity of PE and TE ground. Check
for “Floating” TE, or ground loops
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2-8 Malfunctions with Indications
System Processor Faults
No. Name Description Recovery
SP-00 Ill Fault (Warning) Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-01 Proc OK
SP-10 Queue Bad Dest
(Warning)
Internal processor error was detected and
corrected. An unsolicited reply (possibly
due to noise) from a non-existing device
could cause this warning fault. Operation is
unaffected. Could also be caused by
incorrect block transfer data or byte length.
No action is required or correct block
transfer data.
SP-11 Queue Bad Tag
(Warning
Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-14 Queue RX Msg
Index (Warning)
Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-15 Queue TX Msg
Index (Warning)
Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-16 VP Write Fault
(Warning)
Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-17 CP Write Fault
(Warning)
Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-18 PB Write Fault
(Warning)
Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-19 PA Write Fault
(Warning)
Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-20 VP Read Fault
(Warning)
Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-21 CP Read Fault
(Warning)
Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-22 PB Read Fault
(Warning)
Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-23 PA Read Fault
(Warning)
Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-24 Recv Timeout
(Warning)
Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-25 Bad Channel
Value (Soft)
Internal processor error detected. A
controlled motor stop will be initiated.
Execute a Clear Fault and continue
operation. If the fault reoccurs, replace
Main Control Board.
SP-30 EEPROM None or
Empty (Soft)
Either the EEPROM is not installed or it
has not been initialized. This fault may also
occur if the data in the EEPROM has been
corrupted. All Setup and Configuration
data does not exist and the Drive Start-up
Procedure must be repeated.
Check that the EEPROM is installed in
UMC8 on the Main Control Board.
Execute an “initialize” and repeat the
Drive Start-up Procedure. Clear faults
before attempting to operate the drive.
SP-32 EEPROM Verify
(Soft)
A data write to the EEPROM cannot be
accomplished. This indicates that the
EEPROM component has malfunctioned.
Check J14 Jumper on Main Control
Board for Write Protect Position. If the
fault reoccurs Replace the Main Control
Board and repeat the Drive Start-up
Procedure before attempting to operate
the drive.
SP-35 Handshake VP
(Hard)
Internal communication between
processors has malfunctioned. A
controlled motor stop will be initiated.
Verify DMT has filter installed. Execute
System RESET or cycle power and
attempt normal operation. If the fault
reoccurs, check integrity of TE and PE
grounding before replacing Main Control
Board.
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Malfunctions with Indications 2-9
SP-38 Handshake PB
(Hard)
Internal communication between the
System Processor and the Port B Adapter
Board has Malfunctioned. A controlled
motor stop will be initiated.
Execute System RESET or cycle power
and attempt normal operation. Check the
ribbon connector that plugs into J6 on the
Main Control Board and the Adapter
Board, replace if damage is suspected. If
the malfunction reoccurs, replace the
Adapter Board. If the malfunction still
reoccurs check integrity of TE and PE
grounding before replacing the Main
Control Board.
SP-39 Handshake PA
(Hard)
Internal communication between the
System Processor and the Port A Adapter
Board has malfunctioned. A controlled
motor stop will be initiated.
Execute System RESET or cycle power
and attempt normal operation. Check the
ribbon connector that plugs into J7 on the
Main Control Board and the Adapter
Board, replace if suspect. If the fault
reoccurs, replace the Adapter Board. If
the fault still reoccurs, check integrity of
TE and PE grounding before replacing
the Main Control Board.
SP-43 Port Configd-No
Adapter (Soft)
The System Processor has detected that
an Adapter Board, which has configuration
parameters linked to it, is not installed.
This could result in undesirable operation.
This fault may also occur when trying to
link configuration parameters to
non-existing adapters.
The missing Adapter Board should be
replaced or the configuration parameters
linked to the missing adapter should be
removed. A System RESET can then be
executed and operation continued.
SP-50 Mode VP/CP
Timeout (Hard)
Internal communication between
processors has malfunctioned. A
controlled motor stop will be initiated.
Execute System RESET or cycle power
and attempt normal operation. If the fault
reoccurs, replace Main Control Board.
SP-51 Mode PB Timeout
(Hard)
Internal communication between the
System Processor and the Port B Adapter
has malfunctioned. A controlled motor stop
will be initiated.
Execute System RESET or cycle power
and attempt normal operation. If the fault
reoccurs, replace the Port B Adapter. If
the fault reoccurs, replace the Main
Control Board.
SP-52 Mode PA Timeout
(Hard)
Internal communication between the
System Processor and the Port A Adapter
has malfunctioned. A controlled motor stop
will be initiated.
Execute System RESET or cycle power
and attempt normal operation. If the fault
reoccurs, replace the Port A Adapter. If
the fault persists, replace the Main
Control Board.
SP-53 Processor VP
Faulted (Hard)
The Velocity Processor has been detected
as being in a faulted state. A controlled
motor stop will be initiated.
Check the Fault Queue to see if the
Velocity Processor fault may have been
recorded. These faults must be corrected
before further operation. Execute System
RESET or cycle power and attempt
normal operation. If the fault reoccurs,
replace the Main Control Board.
System Processor Faults
No. Name Description Recovery
!
ATTENTION: Do Not execute a Clear Fault without correcting the cause of the
fault. This will allow the drive to operate and may cause undesirable operation. Th
e
hazard of personal injury or equipment damage exists if faults are not corrected.
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2-10 Malfunctions with Indications
SP-54 Processor PB
Faulted (Soft)
The Port B Adapter has been detected as
being in a faulted state. A controlled motor
stop will be initiated.
Check the Fault Queue to see if the
Adapter fault may have been recorded.
These faults must be corrected before
further operation. Execute a Clear Fault
and attempt normal operation. If the fault
reoccurs, replace the Port B Adapter. If
the fault reoccurs, replace the Main
Control Board.
SP-55 Processor PA
Faulted (Soft)
The Port A Adapter has been detected as
being in a faulted state. A controlled motor
stop will be initiated.
Check the Fault Queue to see if the
Adapter fault may have been recorded.
These faults should be corrected before
further operation. Execute System
RESET or cycle power and attempt
normal operation. If the fault reoccurs,
replace the Port A Adapter. If the fault
occurs again, replace the Main Control
Board.
SP-56 Illegal Mode
Request (Soft)
Internal processor communication error
detected. A controlled motor stop will be
initiated.
Execute a Clear Fault and continue
operation. If the fault reoccurs, replace
Main Control Board.
SP-57 Loc Mode Serial
Timeout (Soft)
This occurs when the Bulletin 1300
Programming Terminal is in LOCAL
CONTROL and serial communication is
interrupted. A controlled motor stop will be
initiated. This fault most often occurs when
the programming terminal has LOCAL
CONTROL and the serial cable to the drive
is unplugged or damaged.
Check the programming terminal
connection to the drive. The connector is
located next to the TB3 terminal strip on
the 1396. Also check the connection on
the programming terminal back if it is a
Door Mounted Terminal (DMT). Execute
a Clear Fault and continue operation. If
the fault reoccurs, replace the
Programming Terminal and/or cable. If
the fault reoccurs again, replace the
cable assembly from the Main Control
Board’s J4 to the D-Shell connector next
to TB3. If the fault is still persistent,
replace the Main Control Board.
SP-58 Task Timeout
(Hard)
Internal processor error detected. A
controlled motor stop will be initiated.
Execute System RESET or cycle power
and attempt normal operation. If the fault
reoccurs, replace Main Control Board.
SP-60 Processor VP
Hard (Hard)
The Velocity Processor has been detected
as being in a Hard Fault state and is
non-operational. A coast stop will be
initiated. This fault usually occurs when the
Velocity Processor has malfunctioned
during power-on diagnostics or has
experienced a major interruption of
operation.
Check the Fault Queue to see if the
Velocity Processor fault may have been
recorded. These faults must be corrected
before further operation. Execute System
RESET or cycle power and attempt
normal operation. Check TE & PE
grounding, if the fault continues to
reoccur, replace the Main Control Board.
SP-61 Processor CP
Hard (Hard)
The Current Processor has been detected
as being in a Hard Fault state and is
non-operational. A coast stop will be
initiated. This fault usually occurs when the
Current Processor has malfunctioned
during power-on diagnostics or has
experienced a major interruption of
operation.
Check the Fault Queue to see if the
Current Processor fault may have been
recorded. These faults must be corrected
before further operation. Execute System
RESET or cycle power and attempt
normal operation. Check TE & PE
grounding, if the fault continues to
reoccur, replace the Main Control Board.
System Processor Faults
No. Name Description Recovery
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Malfunctions with Indications 2-11
SP-62 Processor PB
Hard (Hard)
The Port B Adapter Processor has been
detected as being in a Hard Fault state and
is non-operational. A controlled motor stop
will be initiated. This fault usually occurs
when the Adapter’s processor has failed
power-on diagnostics or has experienced a
major interruption of operation.
Check the Fault Queue to see if the
Adapter’s processor fault may have been
recorded. These faults should be
corrected before further operation.
Execute System RESET or cycle power
and attempt normal operation. If the fault
reoccurs, replace the Port B Adapter.
Check TE & PE grounding, if the fault
continues to reoccur, replace the Main
Control Board.
SP-63 Processor PA
Hard (Hard)
The Port A Adapter Processor has been
detected as being in a Hard Fault state and
is non-operational. A controlled motor stop
will be initiated. This fault usually occurs
when the Adapter’s processor has
malfunctioned during power-on diagnostics
or has experienced a major interruption of
operation.
Check the Fault Queue to see if the
Adapter’s processor fault may have been
recorded. These faults must be corrected
before further operation. Execute System
RESET or cycle power and attempt
normal operation. If the fault reoccurs,
replace the Port A Adapter. Check
grounding, if the fault occurs again,
replace the Main Control Board.
SP-64 VP/CP Flt Mode,
No Status (Soft)
Internal processor communication error
detected. A controlled motor stop will be
initiated.
Execute a Clear Fault and continue
operation. If the fault reoccurs, replace
Main Control Board.
SP-65 PB Flt Mode, No
Status (Soft)
Internal communication between the
System Processor and the Port B Adapter
has malfunctioned. A controlled motor stop
will be initiated.
Execute a Clear Fault and attempt
normal operation. If the fault reoccurs,
replace the Port B Adapter. If the fault
occurs again, replace the Main Control
Board.
SP-66 PA Flt Mode, No
Status (Soft)
Internal communication between the
System Processor and the Port A Adapter
has malfunctioned. A controlled motor stop
will be initiated.
Execute a Clear Fault and attempt normal
operation. If the fault reoccurs, replace
the Port A Adapter. If the fault occurs
again, replace the Main Control Board.
SP-83 Diag EEPROM
(Soft)
The EEPROM checksum calculated during
power-on diagnostics is incorrect. This
usually indicates that data contained in the
EEPROM has been corrupted.
Execute a Clear Fault. Re-initialize
EEPROM again, re-load program and
clear fault If the fault reoccurs often, then
replace the Main Control Board.
SP-85 Diag VP Mbus
(Hard)
Internal processor error occurred during
power-up diagnostics.
Execute System RESET or cycle power
and attempt normal operation. Check
grounding, if the fault reoccurs, replace
Main Control Board.
SP-86 Diag Adapter B
Mbus (Hard)
An internal communication error between
the System Processor and the Port B
Adapter board has occurred during
power-on.
Execute System RESET or cycle power
and attempt normal operation. Check the
ribbon connector that plugs into J6 on the
Main Control Board and the Adapter
Board, replace if damage is suspected. If
the fault reoccurs check grounding first,
then replace the Adapter Board. If the
fault persists, replace the Main Control
Board.
System Processor Faults
No. Name Description Recovery
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2-12 Malfunctions with Indications
Velocity Processor (VP–XX)
The Velocity Processor is responsible for fault monitoring of control
variables throughout the drive. This includes monitoring velocity control,
armature and field outputs to the motor, incoming line conditions, and
communications to the System Processor and Current Processor. These
faults can be induced by problems external to the immediate drive such as a
malfunction of a feedback device, excessive load on the motor, incoming
line variations, etc. An attempt to identify and correct these conditions, if
applicable, must be done prior to replacing components in the drive.
Internal processor faults that occur can be induced by Electrostatic
Discharge (ESD), Electro Magnetic Interference (EMI), excessive heat,
contamination of printed circuit boards (PCB), improper or damaged
connections, etc. An attempt must be made to correct any of these
environmental conditions prior to replacing components in the drive. This
can help reduce the possibility of reoccurrence.
Faults VP-10 through VP-24 are reported in parameter 101 “Drive Fault”
when parameter 630 “Fault Report” is set to a value of 1. The bit
assignments for parameter 101 are given in ( ) where applicable. See Fault
Type Selection.
SP-87 Diag Adapter A
Mbus (Hard)
An internal communication error between
the System Processor and the Port A
Adapter board has occurred during
power-on.
Execute System RESET or cycle power
and attempt normal operation. Check the
ribbon connector that plugs into J7 on the
Main Control Board and the Adapter
Board, replace if damage is suspected. If
the fault reoccurs check grounding first,
then replace the Adapter Board. If the
fault still occurs, replace the Main Control
Board.
SP-90 Serial WDG
Warning
(Warning)
Internal processor error was detected and
corrected. Operation is unaffected.
No action is required.
SP-91 Serial WDG Soft
(Soft)
Internal processor error detected. A
controlled motor stop will be initiated.
Execute a Clear Fault and attempt
normal operation. If the fault reoccurs,
replace Main Control Board.
System Processor Faults
No. Name Description Recovery
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Allen-Bradley 1395 Troubleshooting Manual

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Troubleshooting Manual

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